2010 YAMAHA GRIZZLY 450 maintenance

8-38
8
4. Tighten the locknut.
5. Slide the rubber cover to its original position.
EBU24060Valve clearance The valve clearance changes with use, resulting in
improper air-fuel mixture and/or engine noise. To
prevent this from occurring, the valve clearance
must be adjusted by a Yamaha dealer at the inter-
vals specified in the periodic maintenance and lu-
brication chart.
EBU24071Adjusting the drive select lever safety
system cable The drive select lever safety system cable stretch-
es with use, which can result in improper function.
Therefore, the safety system cable should be
checked and adjusted by a Yamaha dealer at the
intervals specified in the periodic maintenance and
lubrication chart.EBU29601Brakes Replacement of brake components requires pro-
fessional knowledge. Brake service should be per-
formed by a Yamaha dealer.
WARNING
EWB02571Operating with improperly serviced or adjust-
ed brakes could lead to a loss in braking ability
and an accident.
1. Rubber cover
2. Throttle cable free play adjusting bolt
3. Locknut
4. Throttle cable free playU37S61E0.book Page 38 Tuesday, June 2, 2009 10:33 AM

8-39
8
EBU28413Checking the front brake pads and rear
brake friction plates The front brake pads and the rear brake friction
plates must be checked for wear at the intervals
specified in the periodic maintenance and lubrica-
tion chart.TIPThis ATV is equipped with a wet, multiple-disc type
rear brake, which is located inside of the final gear
case.EBU24171Front brake pads
Check each front brake pad for damage and mea-
sure the lining thickness. If a brake pad is dam-
aged or if the lining thickness is less than 1.0 mm
(0.04 in), have a Yamaha dealer replace the brake
pads as a set.
TIPThe wheels need to be removed to check the
brake pads. (See page 8-59.)EBU28421Rear brake friction plates
The rear brake is provided with a wear indicator,
which allows you to check the brake friction plate
wear without having to disassemble the brake. To
check the brake friction plate wear, check the posi-
tion of the wear indicator while applying the brake.
If a brake friction plate has worn to the point that1. Lining thickness
U37S61E0.book Page 39 Tuesday, June 2, 2009 10:33 AM

8-41
8

Refill with the same type of brake fluid. Mixing
fluids may result in a harmful chemical reaction
and lead to poor braking performance.
Be careful that water does not enter the brake
fluid reservoir when refilling. Water will signifi-
cantly lower the boiling point of the fluid and may
result in vapor lock.
Brake fluid may deteriorate painted surfaces or
plastic parts. Always clean up spilled fluid imme-
diately.
As the brake pads wear, it is normal for the brake
fluid level to gradually go down. However, if the
brake fluid level goes down suddenly, have a
Yamaha dealer check the cause.EBU24281Changing the brake fluid Have a Yamaha dealer change the brake fluid at
the intervals specified in the TIP after the periodic
maintenance and lubrication chart. In addition,
have the oil seals of the brake master cylinder and
calipers as well as the brake hoses replaced at the
intervals listed below or whenever they are dam-
aged or leaking.
Oil seals: Replace every two years.
Brake hoses: Replace every four years.
EBU24394Checking the front brake lever free play The brake lever free play must be checked at the
intervals specified in the periodic maintenance and
lubrication chart. The brake lever should have no
free play as shown. If there is free play, have a
Yamaha dealer check the brake system.1. No brake lever free play
U37S61E0.book Page 41 Tuesday, June 2, 2009 10:33 AM

8-42
8
EBU28637Adjusting the brake pedal and rear
brake lever free play and checking the
brake pedal position The brake pedal and brake lever free play and the
brake pedal position must be checked and, if nec-
essary, adjusted at the intervals specified in the
periodic maintenance and lubrication chart.TIP
Always perform this maintenance completely in
the following order whenever adjusting the rear
brake.
When adjusting the rear brake, be sure to adjust
both the brake pedal and the brake lever.
Before adjusting the brake lever and brake pedal
free play, check the rear brake friction plates for
wear.Adjusting the brake pedal and brake lever free
play
The brake pedal free play should measure 17.0–
20.0 mm (0.67–0.79 in). The brake lever free play
should measure 8.0–10.5 mm (0.31–0.41 in). If ei-
ther free play is incorrect, adjust it as follows.
1. Loosen the locknut at the brake lever and fully
turn in the brake lever free play adjusting bolt.
1. Brake pedal free play
1. Brake lever free play
U37S61E0.book Page 42 Tuesday, June 2, 2009 10:33 AM

8-45
8 6. Tighten the locknut at the brake lever.
TIPWhen adjusting the rear brake lever free play:
Be sure not to step on the brake pedal.
Make sure the brake pedal does not move.Checking the brake pedal position
The top of the brake pedal should be positioned
75.0–85.0 mm (2.95–3.35 in) above the footboard.
If the brake pedal position is incorrect, have a
Yamaha dealer adjust it.
EBU24230Axle boots The axle boots must be checked for damage at the
intervals specified in the periodic maintenance and
lubrication chart. Check the axle boots for tears or
damage. If any damage is found, have them re-
placed by a Yamaha dealer.
1. Locknut
2. Brake lever free play adjusting bolt
1. Distance between brake pedal and footboard
U37S61E0.book Page 45 Tuesday, June 2, 2009 10:33 AM

8-49
8
EBU24963Checking the wheel hub bearings The front and rear wheel hub bearings must be
checked at the intervals specified in the periodic
maintenance and lubrication chart. If there is play
in a wheel hub or if a wheel does not turn smoothly,
have a Yamaha dealer check the wheel hub bear-
ings.
EBU24970Lubricating the drive shaft universal
joint The drive shaft universal joint must be lubricated at
the intervals specified in the periodic maintenance
and lubrication chart.
Lubricate the universal joint using a grease gun.Recommended lubricant:
Lithium-soap-based grease
U37S61E0.book Page 49 Tuesday, June 2, 2009 10:33 AM

8-50
8
EBU25021Checking the stabilizer bushes The stabilizer bushes must be checked for cracks
or damage at the intervals specified in the periodic
maintenance and lubrication chart.
Have a Yamaha dealer replace the stabilizer bush-
es if necessary.EBU25051Lubricating the rear knuckle pivots The rear knuckle pivots must be lubricated at the
intervals specified in the periodic maintenance and
lubrication chart.
Lubricate the pivoting points using a grease gun.
EBU25103Lubricating the steering shaft The steering shaft must be lubricated by a Yamaha
dealer at the intervals specified in the periodic
maintenance and lubrication chart. Recommended lubricant:
Lithium-soap-based grease1. Grease nippleRecommended lubricant:
Lithium-soap-based grease
U37S61E0.book Page 50 Tuesday, June 2, 2009 10:33 AM

IIdentification numbers .................................................. 11-1
Indicator lights and warning light .................................... 4-2
Instruments, lights and switches .................................... 5-7KKey identification number ............................................. 11-1LLabel locations ............................................................... 1-1
Light switch .................................................................... 4-6
Low-range indicator light ................................................ 4-3MMain switch .................................................................... 4-1
Maintenance and lubrication chart ................................. 8-5
Maintenance chart, emission control system ................. 8-3
Model label ................................................................... 11-2
Multi-function display ...................................................... 4-4NNeutral indicator light ..................................................... 4-2OOn-Command differential gear lock switch .................... 4-8
On-Command four-wheel-drive switch ........................... 4-7
Override switch .............................................................. 4-6
Owner’s manual and tool kit ........................................... 8-1PPanels, removing and installing ..................................... 8-9
Park indicator light .......................................................... 4-3
Parking ........................................................................... 6-5
Parking on a slope ......................................................... 6-6
Part locations ................................................................. 3-1RRear knuckle pivots, lubricating ................................... 8-50Recoil starter ................................................................ 4-13
Reverse indicator light .................................................... 4-2
Riding your ATV ............................................................. 7-1
SSafety information .......................................................... 2-1
Seat .............................................................................. 4-18
Shock absorber assemblies, adjusting the front and
rear ............................................................................ 4-21
Spark arrester, cleaning ............................................... 8-33
Spark plug, checking .................................................... 8-14
Specifications ............................................................... 10-1
Speed limiter ................................................................ 4-11
Stabilizer bushes, checking .......................................... 8-50
Starter (choke) ............................................................. 4-17
Start switch ..................................................................... 4-6
Steering shaft, lubricating ............................................. 8-50
Storage ........................................................................... 9-2
Storage compartments ................................................. 4-19TTail/brake light bulb, replacing ..................................... 8-57
Throttle cable free play, adjusting ................................ 8-37
Throttle lever ......................................................... 4-11, 5-4
Tires ............................................................................... 5-4
Troubleshooting ........................................................... 8-61
Troubleshooting charts ................................................. 8-62VValve clearance ............................................................ 8-38
V-belt case drain plug .................................................. 8-35
V-belt cooling duct check hose .................................... 8-35
Vehicle identification number ....................................... 11-1WWheel hub bearings, checking ..................................... 8-49
U37S61E0.book Page 2 Tuesday, June 2, 2009 10:33 AM